Alright, time's up: let's talk about having the wrong-sized nuts.
Nah, nothing to be misinterpreted there. Moving on...
Here's something that I don't understand: why aren't battery studs more easily interchangeable? The studs on my batteries are clearly threaded into place, but they also
don't want to move; a 21mm socket on one of them rotated the entire battery instead of loosening the stud...so I kind of gave up at that point and decided to do things the smarter way, instead.
Pictured: Namely, with filing noises.
I guess that day's lesson was: "if you don't have the correct fastener, just make one." So I went over to Tacoma Screw, got US$1.13 worth of 5/16" and 3/8" brass hex nuts and proceeded to
not use a milling machine to make them the correct sizes. I figured that a sharpie and a slightly-dull file that I keep around for gentle work on non-ferrous alloys would be just as quick as the mill, when all things were said and done...and I was right: it took a half-hour to cut the 1/2" and 9/16" across-the-flats measurements of a half-dozen standard-sized nuts down to 12 and 14mm, respectively. And that's how I took one of my favorite pictures in this rambling shambles of a thread, thus far.
Pictured: Mmmmmmm, buttery-soft driveway-bokeh...
Pictured: No edge shall be unchamfered.
Yes, that's a 3/8-16" nut, and yes, I really did put chamfers on all of those edges...and I obviously need the practice because they're not perfectly straight. Also, it's worth mentioning that although I normally don't like custom-made/proprietary fasteners on a vehicle - lookin' at you, Sunbeam, Triumph, Rover, and all of you other poor British excuses for vehicles - what I like even
less is carrying a single SAE-flavored wrench for nothing other than the battery terminals. Sure, I usually carry an adjustable wrench with me, but I have a long and troubled history of mangling battery terminal nuts with adjustable wrenches; I'd like to blame that on the wrench, but in all honesty it's just a byproduct of me being over-9000-levels of inept. I'm also inept with lug crimpers, which is another reason that I bought a lot of extra terminals back in the first posts on this project; naturally, I scrapped a couple trying to figure out which dies I would need to use. Speaking of which: you'd also think that along with easily-interchangeable terminal studs, manufacturers would make standardized lugs and dies...but that is absolutely not the case.
Pictured: Supposedly identical dinguses.
Each of those terminals is supposed to be a 1/0 AWG...and they're all different sizes, both inside and out. Also, those super-heavy Quick Cable lugs on the right are far less malleable than I expected them to be.
Pictured: "Well *there's* your problem..."
So, I bent - and broke - that one because this was going to be the the distal end of the main engine/block ground on the passenger side of the vehicle. I decided to rebuild that cable while I was futzing around with all of this other nonsense, and that particular ground uses a 90° terminal in order to clear the adjacent engine block webbing...and it's now clear to me that although solid copper terminals are usually
very bend-friendly, this terminal was not only not solid copper - look at the fracture - but far more frangible. Kind of makes me wonder what would have happened if I'd crimped it; how's it supposed to flow and cold-weld into the copper wire inside if it can't take more than a 30° bend? Either way, I had some other Quick Cable terminals in the order, and although their sockets were somewhat more thinly-walled, they actually had a really nice, thick stud flange and they crimped beautifully...so I just went with those, and that's what you saw in the previous shots of the stupid-heavy connector cable.
For reference, the sizing of the cables that I replaced is now as follows:
- Main engine/block ground: 2AWG
- Chassis ground immediately adjacent to the forward battery: 4AWG
- Connector between batteries: 1/0AWG
I thought about running 2AWG on the short chassis ground, but it's SO short...so I used cable that I already had, and which was similar to what Toyota provided from the factory; even so, I think I'm about one full gauge larger on both of the two grounds. As time allows I'll go back through and start replacing other grounds with newer, cleaner ones; I still have both 2 and 4AWG in stock, so I should be able to make what I need for any given location. I'll also eventually replace the main starter wire(s) and the alternator wiring as well, but for now a simple cleaning of the factory boot will suffice in that area.
Pictured: And it cleaned up surprisingly well...but there's a problem.
Pictured: The problem.
The astute observer will have already noted that by having changed the cable size and terminal connections between the batteries, I have effectively made the factory Toyota boots somewhat useless...and that's okay, because they were shot. Replacements were sourced from Fastronix; I've used their stuff before and it's good quality...but the reds don't match and I can't sleep anymore, yet again. So, I'm probably going to see about swapping that single remaining factory boot for an aftermarket unit when I rebuild all of the alternator and starter cables, and at that point, everything will match and I'll finally be able to get some rest. And for once, I'm planning ahead on a project and creating a workable sequence of events instead of randomly charging ahead and getting 94% of the way through said project before realizing that I had forgotten to replace the terminal of the 12-volt drop that runs to the rear of the vehicle, which is how this happened:
Pictured: It's like wrapping a burrito, only...not.
If that looks confusing and moronic...well, that's because it is: I used a nylon wire looming over the positive drop to the rear of the vehicle - that's the clipped bit of 8AWG in the photo - and it had heat-shrink over it where it ran all the way to the terminal...so I had to cut everything apart in order to re-make the terminal connection. That led to a bit of fraying and unravelling, so I decided to pull the wire loom back down the wire a bit, close the end with another heat-shrink tube, and then redo the terminal connection...and because the only heat source I had was a torch, I just stuffed a pound of aluminum foil around everything, masked the nylon with a bit of tape, and fired up the torch. It worked pretty well; then, I realized that I could probably have gotten away with electrical tape for this particular connection, and I was right back to feeling stupid. All the same, when everything finally got installed, it looked good.
Pictured: Oh yes.
...and those are the batteries, sorted. The flat military lugs on the forward side will make a 24-volt winch drop super-easy to do, and I have plenty of room for a decent-sized circuit breaker to be installed. I'm also going to throw one of those into the 12-volt drop at the rear; additionally, I'll need to find a red boot for that cable, because the black one that I had to use is also robbing me of sleep. But for all intents and purposes, we're pretty much done; the few things that are left are just cleanup projects. My only concern at this point is the possibility of a dedicated headlight circuit that drops directly off the battery; that might make things a bit crowded with a winch circuit in play...but I'll cross that bridge when I come to it.
And that's pretty much all for this one...for now. Stay tuned.
